JP3274540B2 - Nonwovens made of multicomponent polymer strands containing a mixture of polyolefin and thermoplastic elastomeric material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

FIELD OF THE INVENTION The present invention relates generally to polymeric fabrics, and more particularly to multi-component polymeric nonwovens.

[0002]

BACKGROUND OF THE INVENTION Nonwoven fabrics have various properties which desirably possess certain levels of liquid handling properties such as softness, strength, durability, uniformity, absorbency, liquid barrier properties, and other physical properties. Used to manufacture products. These products include towels, industrial wipers, incontinence products, baby care products such as diapers, sanitary products, and clothing such as medical clothing. These products are often made of multiple layers of nonwoven to obtain the desired combination of properties. For example, disposable diapers made of polymeric nonwovens have a soft, strong, and porous liner layer, a strong, soft outer cover layer, and one or more soft, highly absorbent layers that directly contact the baby's skin. And an intermediate liquid treatment layer.

[0003] Nonwoven fabrics such as those described above are generally made of a melt spun thermoplastic material. These fabrics are called spunbond materials and methods of making spunbond polymeric materials are known. Dorschner et al. US Patent 4,69
No. 2,618, and U.S. Pat.No. 4,340,563, both by Appel et al., Extrude a thermoplastic material through a spinneret and stretch the extruded material into fibers using a high velocity air stream to form a random web on the collection surface. Discloses a method for producing a spunbonded nonwoven fabric from a thermoplastic material. For example, U.S. Pat. No. 3,692,618 to Dorschner et al. Discloses a method of stretching a bundle of polymer fibers with a plurality of stretching guns at very high velocity air. U.S. Pat. No. 4,340,563 to Appel et al. Discloses a method of stretching thermoplastic fibers through a single wide nozzle by a high velocity air stream. The patents listed below also disclose typical melt spinning processes.

[0004] Kemmey US Patent 3,338,992, Kemmey US Patent 3,341,394, Levy US Patent 3,502,538, Hartmann US Patent 3,502,763, Hartmann US Patent 3,909,009, Dobo et al US Patent 3,542,615, Harmon Canadian Patent 803,714.

The desired combination of physical properties, especially softness,
Spunbond materials having a combination of strength and durability have been produced, but have various limitations. For some applications, for example, polymeric materials such as polypropylene may have desirable levels of strength, but not levels of softness. On the other hand, materials such as polyethylene, in some cases, require a level of softness but not a level of strength.

Efforts have been made to produce nonwovens having the desired combination of physical properties, and multi-component or two-component polymeric nonwovens have been developed. Methods for producing two-component nonwoven materials are known and are described in Stanistreet U.S. Pat. No. 4,068,036.
Reissue No. 30,955, U.S. Patent 3,423,2 to Davies et al.
No. 66, U.S. Pat. No. 3,595,731 to Davies et al. The two-component nonwoven is made from a polymer fiber or fiber that contains first and second polymer components as separated. As used herein, "fiber" refers to a continuous strand of material, and "fiber" refers to a cut or discontinuous strand having a finite length. First and second multi-component fibers
Are arranged to occupy substantially separate zones in the cross-section of the fiber and extend continuously along the length of the fiber. Typically, a fiber exhibits the properties of two components because one component exhibits different properties than the other. For example, one component may be relatively strong polypropylene and the other component may be relatively soft polyethylene. As a result, a strong and soft nonwoven fabric is obtained.

[0007] US Patent 3,423,266 to Davies et al.
And U.S. Pat. No. 3,595,731 to Davies et al. Disclose a method of melt spinning bicomponent fibers to form a polymeric nonwoven. The non-woven web may be formed by cutting the melt spun fibers into staple fibers and then forming a bonded culled web, or a continuous web.
The component fibers can be formed by placing them on a forming surface and then bonding the web.

[0008] To increase the bulk (or bulk) of a bicomponent nonwoven web, it is often practiced to crimp bicomponent nonwoven fibers or fibers. US Patents by Davies et al.
The bicomponent fibers may be mechanically crimped and the resulting fibers formed into a nonwoven web, as disclosed in 3,595,731 and 3,423,266, or by using a suitable polymer. If so, a heat treatment of the formed web may activate a potential helical crimp that has been generated in the bicomponent fiber or fiber. Heat treatment is used to activate the potential helical crimps that have been generated in the fiber or fiber after the fiber or fiber has been formed into a nonwoven web.

In particular, in the case of an outer cover material, such as the outer cover layer of a disposable diaper for infants, it is desirable to improve the durability of the nonwoven while maintaining a high level of softness. Abrasion resistance can be increased by increasing the give of the fabric. For example, when a multi-component nonwoven fabric including a softening component such as polyethylene and a high-strength component such as polypropylene is used, the bond between the multi-component strands tends to be separated by a load. To produce a stronger fabric, it is desirable to increase the strength of the bond between these multi-component polymer strands.

[0010]

Accordingly, a need exists for nonwoven fabrics having increased levels of softness and durability, especially for applications such as outer cover materials and clothing materials for personal care products. . It is an object of the present invention to provide an improved nonwoven and a method for producing it.

It is another object of the present invention to provide a nonwoven fabric having a desirable combination of physical properties such as softness, strength, durability, uniformity, and absorbency, and a method of making the same. is there. Another object of the present invention is to provide a soft yet durable non-woven outer cover material for absorbent personal care products such as disposable diapers for infants.

It is a further object of the present invention to provide a soft yet durable non-woven garment material for items such as medical garments.

[0013]

As described above, the present invention provides a nonwoven fabric comprising a multi-component polymer strand, wherein one component of the nonwoven fabric comprises a mixture of a polyolefin and a thermoplastic elastomeric polymer. . By adding a thermoplastic elastomeric polymer, the bonds between the strands of the fabric are not easily broken and the abrasion resistance of the fabric is increased. In particular, the thermoplastic elastomeric polymer increases the elasticity of the fabric strands at the point of attachment of the fabric, so that the fabric has more elasticity and higher abrasion resistance. At the same time, the thermoplastic elastomeric polymer does not impair the softness of the fabric.
The properly bonded nonwoven fabric of the present invention is particularly suitable for use as an outer cover material in personal care products, such as disposable diapers for infants, or as a garment material. The fabric of the present invention, when used as an outer cover material, can be laminated to a thin film of a polymeric material such as polyethylene.

More specifically, the nonwoven fabric of the present invention comprises an extruded multi-component polymer strand containing first and second polymer components, wherein the first and second components are within the cross-section of the multi-component strand. They are arranged to occupy substantially separate zones and extend continuously along the length of the multicomponent strand. The second component constitutes at least a portion of the peripheral surface of the multi-component strand along the length of the multi-component strand and includes a mixture of a polyolefin and a thermoplastic elastomeric polymer. Bonds between the multi-component strands can be formed by applying heat. As mentioned above, the addition of the thermoplastic elastomeric polymer increases the elasticity of the bond between the strands of the fabric.

More specifically, A and A 'are each a thermoplastic end block composed of a styrenic moiety (moiety), B is an elastomeric poly (ethylene-butylene) midblock, and the thermoplastic elastomeric polymer is A-A. It is preferred to be composed of a three-block copolymer BA ′. The thermoplastic elastomeric polymer may also include a two-block copolymer AB, where A is a thermoplastic end block composed of a styrene-based portion and B is an elastomeric poly (ethylene-butylene) block. As described in more detail below, thermoplastic elastomeric polymers or compounds suitable for use in the present invention are available from Shell, Houston, Texas.
Commercially available from Chemical Company under the trade name KRATON.

More specifically, the mixture of the second component within the multi-component strand of the present invention also includes a tackifying resin to improve the bonding of the multi-component strand. Suitable tackifying resins include hydrogenated hydrocarbon resins and terpene hydrocarbon resins. Alpha methyl styrene is a particularly suitable tackifying resin. Further, the mixture of the second component in the multi-component strand of the present invention preferably comprises a viscosity reducing polyolefin to improve the ease of processing of the multi-component strand. A particularly suitable viscosity reducing polyolefin is polyethylene wax. Polyolefins suitable for the blend of the second component in the multicomponent strand of the present invention are polyethylene and copolymers of ethylene and propylene. Polyolefins particularly suitable as the second component include linear low density polyethylene. The second component of the multi-component strand of the invention is the first component of the multi-component strand.
It is preferable to have a melting point lower than the melting point of the component.

The first component also preferably comprises a polyolefin, but may comprise another thermoplastic polymer such as a polyester or a polyamide. Suitable polyolefins for the first component of the multicomponent strand of the present invention include polypropylene, copolymers of propylene and ethylene, and poly (4-methyl-1-pentene). The first and second components can be selected such that the first component provides strength to the fabric of the present invention and the second component provides softness. As mentioned above, the addition of a thermoplastic elastomeric polymer increases the elasticity of the fabric, thereby increasing the abrasion resistance of the fabric.

More specifically, the first polymeric component of the multicomponent strand of the present invention comprises from about 20 to about 20 strands of the strand.
The second polymer component is present in an amount of about 80% to about 20% by weight of the strand. Also, the thermoplastic elastomeric polymer may comprise from about 5 to about 20 of the second component.
% By weight, wherein the polyolefin comprises about 2% of the second component.
Preferably it is present in an amount of from 80 to about 95% by weight.
Further, the mixture of the second component may comprise from more than 0 to about 10% by weight of the viscosity-imparting resin and from more than 0 to about 10%
It is preferable to include a polyolefin for reducing viscosity up to.

According to another aspect of the present invention, there is provided a composite nonwoven fabric. The composite fabric of the present invention comprises a first web of extruded multi-component polymer strands, the first web comprising, as described above, the polyolefin and thermoplastic elastomer weight in the second component of the multi-component strand. It comprises a multi-component polymer strand having a blend of coalescing. The composite fabric of the present invention also includes a second web of extruded polymer strands, the first and second webs being positioned in a layered surface relationship with one another and bonded together to form a single piece of fabric. Is formed. The addition of a thermoplastic elastomeric polymer to the second component of the first multi-component strand increases the elasticity of the bond between the first and second webs. This improves the wear resistance of the overall composite fabric.

In particular, the strands of the second web of the present invention can be formed by conventional melt blowing techniques. More specifically, the strands of the second web preferably include a second blend of a polyolefin and a thermoplastic elastomeric polymer. The presence of the thermoplastic elastomeric polymer in the first and second webs increases the durability of the bond between the webs and the overall durability of the composite fabric.

[0021] Still more specifically, the composite fabric of the present invention comprises a third of an extruded multi-component polymer strand comprising first and second polymer components arranged as in a first web. The second component preferably comprises a third mixture of a polyolefin and a thermoplastic elastomeric polymer. The first web is bonded to one side of a second web, and the third web is bonded to the opposite side of the second web. By including a thermoplastic elastomeric polymer,
The bond between the three webs and the overall durability of the composite fabric is enhanced.

Further objects and the scope of application of the invention will become clear from the description hereinafter. However, the following detailed description of the preferred embodiments of the present invention is by way of example only, and those skilled in the art will be able to devise various changes and modifications without departing from the spirit and scope of the present invention.

[0023]

DETAILED DESCRIPTION OF THE INVENTION As mentioned above, the present invention provides a soft, durable, real cloth (i.e., cloth) -like nonwoven made of a multi-component polymer strand. The nonwoven fabric of the present invention,
It consists of an extruded multi-component strand containing a mixture of a polyolefin and a thermoplastic elastomeric polymer as one of the components. The thermoplastic elastomeric polymer provides resilience at the points of connection between the multi-component strands, thereby better distributing the stress of the fabric. As a result, the fabric of the present invention has high tensile energy and abrasion resistance while maintaining a high level of softness.

The fabrics of the present invention are particularly useful for use as outer cover materials and clothing materials for personal hygiene products. Suitable personal care products include infant care products such as disposable diapers, infant care products such as training pants, and adult care products such as incontinence and sanitary products. Suitable clothing includes medical clothing, work clothes, and the like.

The present invention further provides a first web of a nonwoven fabric comprising a multi-component polymer strand as described above, and a first web bonded to the first web in a layer-to-surface relationship with the first web. A second web of extruded polymer strands. According to a preferred embodiment of the present invention, the composite comprises a third web of extruded multi-component polymer strands, the third web being bonded to the opposite side of the second web to form a three-layer composite. Forming the structure. Each layer is
Mixtures of polyolefins and thermoplastic elastomeric polymers can be included to improve the overall wear resistance of the composite fabric.

"Strand" as used herein
An elongated extrudate formed by passing the polymer through a forming orifice such as a die. Strands include fibers, which are discontinuous strands of finite length, and fibers (or filaments), which are continuous strands of material. The nonwoven fabric of the present invention can be formed from multi-component staple fibers. These staple fibers can be caged and bonded to form a nonwoven. Preferably, however, the nonwovens of the present invention are made of continuous spunbond multicomponent fibers disposed on an extruding, stretching and running forming surface. Details of a preferred process for producing the nonwoven fabric of the present invention will be described later.

As used herein, the terms "nonwoven web" and "nonwoven" are used without the use of a braiding process to produce the structure of individual strands that are braided together in a similar iterative manner. Used interchangeably to refer to a web of a given material. Nonwoven webs can be formed by various processes, such as a melt blowing process, a spun bond process, a film aperture process, and a staple fiber culling process.

[0028] The fabric of the present invention comprises an extruded multi-component polymer strand consisting of first and second polymer components. The first and second components are arranged to occupy substantially separate zones within the cross-section of the multi-component strand, and extend continuously along the length of the multi-component strand. The second component constitutes a portion of the peripheral surface of the multicomponent strand continuously along the length of the multicomponent strand, and includes a mixture of a polyolefin and a thermoplastic elastomeric polymer.

A preferred embodiment of the present invention is a polymeric nonwoven fabric comprising continuous bicomponent fibers comprising a first polymeric component A and a second polymeric component B. The first and second components A and B can be arranged side by side as shown in FIG. 2 or in an eccentric sheath / core arrangement as shown in FIG. It has a high degree of spiral crimp. A polymer component A having a strand core,
The polymer component B is used as a sheath / core-arranged sheath. The first and second components can also be formed in a concentric sheath / core arrangement as shown in FIG. Methods of extruding multi-component polymer strands into these arrays are known to those skilled in the art. Although the invention is described below as including bicomponent fibers, it is understood that the fabrics of the invention also include strands having more than two components.

The first component A of the multi-component strand preferably has a higher melting point than the second component. More preferably, the first component A comprises a polyolefin,
Comprises a mixture of a polyolefin and a thermoplastic elastomeric material. Polyolefins suitable as the first component include polypropylene, random copolymers of propylene and ethylene, and poly (4-methyl-1-pentene), where the first component A is other than a polyester or polyamide. May be made of a thermoplastic polymer. Suitable polyolefins for the second component B include polyethylene and random copolymers of propylene and ethylene.
Preferred polyethylenes for the second component B are linear low density polyethylene, low density polyethylene, and high density polyethylene.

Preferred combinations of the polymers as components A and B are (1) polypropylene as the first component A,
Also, a mixture of linear low-density polyethylene and a thermoplastic elastomeric polymer as the second component B, (2) polypropylene as the first component A, and a random copolymer of ethylene and propylene as the second component B It includes a mixture or compound of a polymer and a thermoplastic elastomeric polymer. Suitable materials for preparing the multi-component strands of the fabrics of the present invention include PD-3445 polypropylene from Exxon, Houston, Texas, random copolymers of propylene and ethylene from Exxon, and Dow Che, Midland, Michigan.
mical Company, ASPUN 6811A, 6808A, and 6817 linear low density polyethylene.

Suitable thermoplastic elastomeric polymers include thermoplastic materials which can be formed into a sheet or film and stretched by applying a biasing force to a certain stretched and biased length. . This length is at least about 1 of the relaxed length when no bias is applied.
25% and recovers at least 25% of its growth when released from bias. Thermoplastic elastomeric polymers have the properties described above when they are in substantially pure form or when mixed with additives, plasticizers and the like. The mixture obtained when mixed with a polyolefin according to the invention is not an elastomer,
It has some elastomeric properties. In a hypothetical example that satisfies the above definition of elastomer, at least 1.2
A 1 inch material sample that can be stretched to 5 inches and stretched to a minimum of 1.25 inches recovers to a length not exceeding 1.875 inches.

"Recovery" refers to the contraction of the stretched material when the biasing force is terminated after the biasing force has been applied to stretch the material. For example, if a material having a length of 1 inch in an unbiased relaxed state is stretched to a length of 1.5 inches, the material is stretched 50% and its relaxed length is reduced to 50%. It has a length that has been stretched to 150%. After releasing the bias or stretching force,
If the material had recovered to a length of 1.1 inches, it had recovered 80% of its elongation.

Preferred thermoplastic elastomeric polymers suitable for the present invention are those wherein A and A 'are each poly (vinyl-allene)
A thermoplastic endblock containing a styrenic moiety, such as, B, an elastomeric polymer midblock, such as a poly (ethylene-butylene) midblock;
It includes a triblock copolymer having a general shape of B-A '. The ABA ′ triblock copolymer can have different or identical thermoplastic block copolymers as A and A ′ blocks, and can also include linear block copolymers, branched block copolymers, and radial block copolymers. Block copolymers can be included. The radial block copolymer is (AB)
_m- X. Here, X is a polyfunctional atom or molecule, and each (A) is such that A is an end block.
-B) _m- radiates from X. In the emissive block copolymer, X can be an organic or inorganic polyfunctional atom or molecule, and m is an integer having the same value as the first functional group present in X. The integer m is usually at least 3
And often 4 or 5, but is not limited to these.

The thermoplastic elastomeric polymer used in the present invention is a two-block copolymer AB, wherein A is a thermoplastic end block composed of a styrene-based portion, and B is a poly (ethylene-butylene) block. Can also be included. The thermoplastic elastomeric polymer is ABA′3.
It is preferable to include a block copolymer and a diblock copolymer AB. The three-block copolymer and the two-block copolymer suitable for the present invention include all block copolymers having a rubbery block and the above-mentioned thermoplastic block, and these are mixed with a polyolefin suitable for the present invention, It can be extruded as one component of a multi-component strand.

A preferred thermoplastic elastomeric copolymer suitable for the present invention is KRA from Shell Chemical Company.
Includes an ABA 'triblock copolymer commercially available as TON G-2740. KRATON G-2740 is an ABA 'triblock styrene-ethylene-butylene copolymer, and A
-B2 A mixture containing a block styrene-ethylene-butylene copolymer, a tackifier, and a polyolefin for reducing viscosity. KRATONG-2740 contains 63% by weight of the copolymer blend, 20% by weight of a viscosity controlling polyolefin,
And 17% by weight of a tackifying resin. KRATON G-274
The copolymer mixture in 0 is 70% by weight of ABA'3
It contains a block copolymer and 30% by weight of an AB2 block copolymer. The molecular weight of the end blocks A and A 'of the triblock copolymer and the diblock copolymer is about 5,300.
It is. Elastomeric block B of triblock copolymer
Has a molecular weight of about 72,000, and the molecular weight of the two-block copolymer elastomeric block B is about 36,000.

The tackifying resin in KRATON G-2740 is Her
REGALREZ 1126 hydrogenated hydrocarbon resin available from cules, Inc. This type of resin contains alpha methyl styrene, as compared to a copolymer mixture of KRATON G-2740 and the second component B polyolefin. KR
The polyolefin wax in ATON G-2740 is Eastman C
EPOLENE C-10 available from the Chemical Company. Initially, the polyolefin in KRATON G-2740 was purchased from Quantum Chemical Corporation, Cincinnati, Ohio.
Petrothene NA601 (PE NA) from USI Division
601).
EPOLENE C-10 and PE NA601 are compatible. Qua
According to information obtained from ntum Chemical Corporation, PE NA601 is a low molecular weight, low density polyethylene with applications in the area of high temperature melt adhesion and coatings. US
I. also states that PE NA601 has the following nominal values: (1) Brookfield viscosity cP is 8,500 at 150 ° C and 3,300 at 190 ° C in a measurement according to ASTM D 3236. (2) The density is 0.903 g / cm ³ in the measurement according to ASTM D 1505. (3) The equivalent melt index is 2,000 g / 10 min according to the measurement according to ASTM D 1238. (4) The ring and sphere softening point is 102 ° C in the measurement according to ASTM E28. (5) The tensile strength is 850 pounds per square inch as measured according to ASTM D 638.
(6) Elongation is 90% as measured according to ASTM D 638. (7) The transverse elastic modulus (or rigidity) at 34 ° C is T
_F (45,000). (8) Hardness (1/10 mm) at 77 ° F (Fahrenheit) is 3.6.

KRATON G-2740 is a preferred blend of thermoplastic elastomeric polymers, but adds a tackifying resin, a viscosity reducing polyolefin, and other such materials to the second component B polyolefin. be able to. However, these materials are compatible with (ie, mixed with) the second component B so that the second component B can be extruded with the first component A to form the other component strand of the present invention. Which does not cause chemical action). For example, Regalrez 1094, 3102, and 6108
Hydrogenated hydrocarbon resins such as described above can also be used in the present invention. Further, ARKON P series hydrogenated hydrocarbon resins available from Arakawa Chemical (USA) are also suitable tackifying resins for use with the present invention. Also, terpene hydrocarbon resins such as ZONATAC501 Lite are suitable tackifying resins. Of course, the present invention is not limited to these tackifying resins, and other tackifying resins compatible with the composition of Component B and capable of withstanding high processing temperatures can also be used.

Other viscosity reducing materials can be used in the present invention, as long as the separated viscosity reducing material is compatible with component B. The tackifier resin can also function as a viscosity reducing material. For example, a low molecular weight hydrocarbon resin such as Regalrez 1126 can function as a viscosity reducing material. Although the main components of the multicomponent strand of the present invention have been described above, these polymer components can also include other materials that do not interfere with the purpose of the present invention. For example, polymer components A and B include, but are not limited to, pigments, antioxidants, stabilizers, surfactants, waxes, flow aids, solid solvents, added to enhance the ease of processing of the composition. Particles and materials used.

According to a preferred embodiment of the present invention, the multicomponent strand comprises about 20 to about 80% by weight of the first polymer component A and about 80 to about 20% by weight of the second polymer component B.
And Preferably, the second component B comprises about 80 to about 95% by weight of a polyolefin and about 5 to about 20% by weight of a thermoplastic elastomeric polymer. Further, it is preferred that the second component B also comprises more than 0 to about 10% by weight of a tackifying resin and more than 0 to about 10% by weight of a viscosity reducing polyolefin. The thermoplastic elastomeric polymer contains about 40 to about 95% by weight of AB-
A 'triblock copolymer and about 5 to about 60% by weight of A
-B2 block copolymer.

According to a preferred embodiment of the present invention, the nonwoven is composed of 50% by weight of polymer component A and 5
Continuous spunbond 2 comprising 0% by weight of polymer component B
The polymer component A comprises 100% by weight of polypropylene and the polymer component B comprises 90% by weight of polyethylene and 10% by weight of a KRATON G-2740 thermoplastic elastomeric block copolymer compound. I have. In an alternative embodiment, the polyethylene in the second polymer component B has been replaced by a random copolymer of ethylene and propylene.

FIG. 1 shows a processing line 10 for preparing a preferred embodiment of the present invention. Although the processing line 10 is arranged to produce bicomponent continuous fibers, it should be understood that the present invention also encompasses nonwoven fabrics made of multicomponent fibers having more than two components. For example, the fabric of the present invention can be made of fibers having three or four components. The invention further includes non-woven fabrics comprising single-component strands in addition to multi-component strands. In such an embodiment, the single component and multiple component strands can be combined to form a single, unitary web.

Processing line 10 includes a pair of extruders 12a for extruding polymer component A and polymer component B separately.
And 12b. The polymer component A is the first hopper 14a
Is supplied to the associated extruder 12a, and the polymer component B is supplied from the second hopper 14b to the associated extruder 12b. Polymer components A and B are extruded 12a and 12
b to the spinneret 18 through respective polymer conduits 16a and 16b. Spinnerets for extruding bicomponent fibers are well known to those skilled in the art, and thus need not be described in detail. Briefly, the spinneret 18 has a pattern of openings adapted to create a flow path that separately guides the polymer components A and B through the spinneret, a plurality of which are stacked one above the other. A housing containing a spin pack including the plate of The spinneret 18 has openings arranged in one or more rows. The spinneret opening forms a curtain of fibers that extend downward as the polymer is extruded through the spinneret. If a high level of crimp is desired, the spinneret 18 can be arranged to form side-by-side bicomponent fibers or eccentric sheath / core bicomponent fibers. Such an arrangement is shown in FIGS. If high levels of crimp are not desired, spinneret 18 can be arranged to form the concentric / core bicomponent fibers shown in FIG.

The processing line 10 also includes a cooling blower 20 positioned near a curtain of fibers extending from the spinneret 18. Air from the cooling blower 20 cools the fibers extending from the spinneret 18. The cooling air can be directed from one side of the fiber curtain as shown in FIG. 1 or from both sides of the fiber curtain.

A fiber stretching or suction device 22 is positioned below the spinneret 18 and receives the cooled fibers. Fiber stretchers or suction devices used to melt spin a polymer are known, as described above. Fiber stretching devices suitable for use in the process of the present invention include a linear fiber suction device of the type shown in U.S. Patent 3,802,817 and a drawer of the type shown in U.S. Patents 3,692,618 and 3,423,266. Including guns.

In general, the fiber stretcher 22 includes an elongated vertical passage through which fibers are drawn by suction air entering from one side of the passage and flowing downward through the passage. The suction air stretches the fibers and draws ambient air through the fiber stretching device. If a high degree of natural spiral crimp is desired in the fiber, the suction air is heated by heating device 24.

A seamless perforated surface 26 is positioned below the fiber stretcher 22 and receives continuous fibers from the outlet opening of the fiber stretcher. Forming surface 26
Runs around the guide roller 28. Vacuum device 30 positioned below forming surface 26 on which fibers are deposited
Attract the fibers to the forming surface. Processing line 1
0 also includes a compression roller 32 which, together with the frontmost guide roller 28, receives the web peeled from the forming surface 26. Further, the processing line 10 includes a calender roller 34 for thermal point bonding that combines the bicomponent fibers into a web to form a finished fabric. Finally, the processing line 10 includes a take-up roller 42 for winding the finished cloth.

To operate the processing line 10, the hoppers 14a and 14b are loaded with the polymer components A and B, respectively. Polymer components A and B are melted and extruded through polymer conduits 16a and 16b and spinneret 18 by respective extruders 12a and 12b. The temperature of the molten polymer will vary depending on the polymer used, but when using polypropylene and polyethylene as components A and B, respectively, the preferred temperature of the polymer is from about 370 to about 500 ° F, More preferably 400 to about 4
In the range of 50 ° F.

As the extruded fibers extend below the spinneret 18, the air flow from the cooling blower 20 at least partially cools the fibers, creating a potential helical crimp in the fibers. The cooling air flows in a direction substantially perpendicular to the length of the fibers, preferably at a temperature in the range of about 45 to about 90 ° F., and a speed of about 100 to about 400 feet / minute.

After cooling, the fibers are drawn in the vertical passage of the fiber stretcher 22 by the air flow through the fiber stretcher. The fiber stretching device 22 is moved from the bottom of the spinneret 18.
Preferably, it is positioned 30 to 60 inches below. If a fiber is desired that has a minimal natural helical crimp, the suction air is at ambient temperature. If a fiber having a high crimp is desired, heated air is supplied from the heating device 24 to the fiber stretching device 22. If a high crimp is desired, the temperature of the air supplied from the heating device 24 will be the temperature required to activate the potential crimp, even after the cool ambient air drawn in with the fibers has been mixed and cooled to some extent. To a temperature sufficient to heat the fibers up to The temperature required to activate the potential crimp of the fiber ranges from about 110 ° F. to a maximum temperature below the melting point of the second component B. The temperature of the air from the heating device 24, and thus the temperature at which the fibers are heated, can be varied to achieve different levels of crimp. It should be understood that the temperature of the suction air to achieve the desired crimp depends on factors such as the type of polymer in the fiber and the denier of the fiber.

Generally speaking, the higher the air temperature, the greater the number of crimps. The degree of crimping of the fibers can be controlled by controlling the temperature of the air in the fiber stretcher 22 that contacts the fibers. For this reason, simply adjusting the temperature of the air in the fiber stretching device 22,
It is possible to vary the density, pore size distribution, and drape of the fabric. The stretched fiber is supplied to a fiber stretching device 2
It is deposited on the running forming surface 26 through two outlet openings. Vacuum device 20 attracts the fibers to forming surface 26 to form an unbonded nonwoven web of continuous fibers. The web is then lightly compressed by compression rollers 32 and thermally point bonded by rollers 34. Since the technique of thermal point bonding is known to those skilled in the art, a detailed description thereof will be omitted. Thermal point bonding according to US Pat. No. 3,855,046 is preferred. The type of bond pattern can be varied depending on the desired degree of fabric strength. The bonding temperature may also vary depending on factors such as the polymer in the fiber. As described below, thermal point bonding produces materials close to genuine cloth used as outer coverings for absorbent personal care products, such as infant diapers, and clothing, such as medical clothing. Is preferred. Such a thermally point bonded material is shown in FIG.

Finally, the finished web is taken up on take-up rollers 42 and is ready for further processing or use. When used to make liquid absorbent articles, the fabrics of the present invention can be treated with conventional surface treatments or can include conventional polymeric additives to enhance the wettability of the fabric. For example, the fabric of the present invention can be treated with a polyalkali oxide-modified siloxane and a silane, such as the polyalkali oxide-modified polydimethylsiloxane described in US Pat. No. 5,057,361. Such a surface treatment enhances the wettability of the fabric, making it suitable as a liner or surge management material for sanitary products, infant care products, infant care products, adult incontinence products. The fabric of the present invention can also be treated with other treating agents such as antistatic agents, alcohol water repellents, and the like, which are known to those skilled in the art.

The material obtained is soft and durable. The addition of a thermoplastic elastomeric material enhances the abrasion resistance and elasticity of the fabric without compromising the softness of the fabric. Thermoplastic elastomeric polymers or composites provide resilience at the points of connection between the multicomponent fibers and can provide better stress distribution in the fabric. Although the bonding method shown in FIG. 1 is thermal point bonding, the fabric of the present invention may be bonded by other means such as oven bonding, ultrasonic bonding, or hydraulic entangling, or a combination thereof. It should be understood that a real cloth can be manufactured. These joining techniques are well known to those skilled in the art and will not be described in detail. If a more lofty material is desired, the fabric of the present invention may be joined by non-compressive means such as a vented (or through-air) joint. Methods of vent bonding are known to those skilled in the art. Briefly, the fabric of the present invention can be ventilated with forced air having a temperature above the melting point of the second component of the fiber as the fabric passes over the perforated rollers. Hot air melts the polymer component B having the lower melting point, thereby forming a bond between the bicomponent fibers and consolidating the web. Such high loft materials are useful as fluid management layers in absorbent personal care products such as infant diaper liners or surge materials.

According to another aspect of the present invention, the above described nonwoven can be laminated to one or more polymeric nonwovens to form a composite material. For example, the outer cover material
It can be formed by laminating the spunbonded, nonwoven, thermally point bonded fabric described above to a polyethylene film. The polyethylene film acts as a liquid barrier. Such an embodiment is particularly suitable as an outer cover material.

In accordance with yet another aspect of the present invention, a first web of extruded multi-component polymer strand made as described above comprises a first web and a second web in a layered surface. The extruded multi-component polymer strand is bonded to the second web so that it is positioned in a surface-to-surface relationship. Second
The web may be a spunbond material, but in applications such as garment materials for medical garments, the second layer can be made by known melt blowing techniques. The melt blown layer acts as a liquid barrier. Such a melt blowing technique can be performed according to US Pat. No. 4,041,203. This patent refers to the following published books regarding melt blow technology. Washington D. C. INDUSTRIAL & ENGINEERIN describing his work at the Naval Research Institute
G CHEMISTRY, Vol. 48, No. 8, pp. 1342-1346, "Ultrafine Thermoplastic Fiber," Nav., April 15, 1954.
al Research Laboratory Report 111437, United States Patent
3,715,251, 3,704,198, 3,676,242, 3,
595,245, UK specification 1,217,892.

The melt blown layer can be of substantially the same composition as the second component B of the multi-component strand in the first web. The two layers are thermally point bonded together to form a real cloth-like material. The first and second webs are bonded together and the thermoplastic elastomeric polymer is a second component B of both the first and second webs.
When present within, the bond between these webs is stronger and the wear resistance of the composite material is increased.

As with the first web, a third layer of the nonwoven web of multicomponent polymer strands can be bonded to the second web on the side opposite the first web. If the second web is a melt blown layer, the melt blown layer is sandwiched between two layers of multi-component material. Such a material 50, shown in FIGS. 5 and 6, provides a relatively soft layer of fabric 54 that provides softness and feel to both sides.
And 56, which is advantageous as a medical garment material. Preferably, material 50 is thermally point bonded. When thermally point bonded, the individual layers 52, 54, and 56 fuse together at a bonding point 58.

The composites may be formed separately and then bonded together, or they may be formed in a continuous process such that one web is formed on another web. Both of these processes are well known to those skilled in the art and will not be described in detail. U.S. Pat. No. 4,041,203 discloses a continuous process for making these composites.

The following Examples 1-13 are intended to illustrate particular embodiments of the present invention and to explain to one skilled in the art the manner in which the present invention may be practiced. Comparative Examples 1 to 3 show the advantages of the present invention. It is to be understood that the parameters of the present invention may vary slightly depending on the particular processing equipment used and the ambient conditions. A nonwoven web composed of a comparative monocontinuous bicomponent fiber was produced using the process shown and described in FIG. The fiber configuration is eccentric sheath / core type, with a weight ratio of sheath to core of 1: 2.
Spinhole geometry 0.6 m with L / D ratio of 4: 1
m D and the spinneret has 525 openings arranged at 50 openings / inch in the machine direction. Core composition is PD-3445 polypropylene from Exxon, Houston, Texas 1
The pod composition contained 100% by weight ASPUN 6811A linear low density polyethylene from Dow Chemical Company, Midland, Michigan. The spin pack temperature was 430 ° F and the spin hole throughput was 0.7 GHM. The cooling air flow rate was 37 scfm and the cooling air temperature was 55 ° F. Suction device air temperature is 55
° F and the manifold pressure was 3 psi. The resulting web was thermally point bonded at a bonding temperature of 245 ° F. The bond pattern has regularly spaced bond areas of 270 bond points per square inch and a total bond area of about 18%.

Example 1 A nonwoven web composed of continuous bicomponent fibers was produced according to the process described in Comparative Example 1 . However, pods are 90% by weight ASPUN 6811A polyethylene and 10% by weight KRA
TON G-2740 thermoplastic elastomeric block copolymer (manufactured by Shell Chemical Company, Houston, TX).

Example 2 A nonwoven web consisting of continuous bicomponent fibers was produced according to the process described in Comparative Example 1. However, pods are 80% by weight ASPUN 6811A polyethylene and 20% by weight KRA
It consists of a TON G-2740 thermoplastic elastomeric block copolymer compound.

Example 3 A nonwoven web consisting of continuous bicomponent fibers was produced according to the process described in Comparative Example 1. However, pods are 90% by weight of a random copolymer of propylene and ethylene (Exxon, Houston, Texas) and 10% by weight of K
RATON G-2740 consists of a thermoplastic elastomeric block copolymer compound.

The fabric samples of Comparative Example 1 and Examples 1-3 were tested to determine physical properties. Grab tension is ASTM
It is measured according to D 1682 and is
n Burst) is a measure of the fabric's resistance to bursts,
Measured according to STM D 3786, drape stiffness is AST
Measured according to MD 1388. Trapezoidal tear is a measure of the tear strength of a cloth under a steady increasing load parallel to the length of the material. Trapezoidal tearing was measured according to ASTM D 1117-14, except that the tearing load was calculated as the average of the first and highest peaks rather than the average of the lowest and highest peaks.

The Martindale abrasion test
A test using a Martindale tester to measure resistance to pill formation and other related surface changes on woven fabric under light pressure. Martindale abrasion is measured using ASTM D4 except that the value obtained is the number of cycles required by the Martindale tester to create a 0.5 inch hole in the fabric sample.
Measured according to 970-89.

The cup crushing test is to evaluate the stiffness of the cloth. In order to maintain the uniform deformation of the cup-shaped cloth, the cup-shaped cloth is surrounded by a cylinder having a diameter of about 6.5 cm, while the diameter of the cup-shaped cloth is about 6.5 cm. Measure the peak load required for a 4.5 cm diameter hemispherical foot to break a 9 "x 9" piece of cloth formed into an inverted cup shape 6.5 cm deep. The feet and cups are aligned to avoid contact between the cup wall and the feet to affect peak load. The peak load was measured at Pensauken, NJ, while lowering the foot at a rate of about 0.25 inches / second.
Schaevitz Company model FTD-G-500 load cell (5
(00 g range). Table 1 Properties vs. 1 example 1 example 2 example 3 Actual basis weight 1.01 1.15 1.20 1.14 Grab tensile MD peak energy (in-lb) 47.30 51.99 46.46 31.22 MD peak load (lb) 20.69 20.37 20.78 25.24 CD peak energy (in) -lb) 47.30 42.15 41.51 25.83 CD peak load (lb) 12.77 12.77 14.49 17.92 MD trapezoid tear (lb) 12.90 12.60 13.90 12.50 CD trapezoid tear (lb) 7.70 7.70 8.90 8.10 Martindale wear (cycle / 0.5 "hole) 82 153 163 231 MD drape stiffness (in) 2.70 3.87 2.76 2.90 CD drape stiffness (in) 1.72 1.77 1.84 2.66 Cup crushing / peak load (g) 55 72 77 128 Cup crushing / total energy (g / mm) 985 1339 1381 2551 Mullenburst ( psi) 19.70 19.08 21.20 29.40 As is evident from the data in Table 1, the abrasion resistance of the samples of Examples 1-2 is significantly greater than the abrasion resistance of Comparative Example 1. This is the second component of the multicomponent fiber. A thermoplastic elastomeric block copolymer compound Other strength properties such as grab tension, trapezoidal tearing, and Mullenburst of the samples of Examples 1-2 are as follows:
These strength characteristics are smaller than the other strength characteristics of Comparative Example 1, but show no substantial difference. Similarly, there is no substantial difference between the stiffness of the sample of Example 1-2 and the stiffness of the sample of Comparative Example 1, as shown by the drape stiffness and cup break data in Table 1. This demonstrates that the thermoplastic elastomeric block copolymer composite increases the abrasion resistance and durability of the multicomponent nonwoven without significantly affecting the strength properties and feel of the fabric. The data for the sample of Example 3 in Table 1 shows various characteristics of the examples of the present invention in which the sheath component is composed of a random copolymer of propylene and ethylene.

A spunbond nonwoven fabric was prepared according to the process described for Comparative 2 vs. Comparative 1. However, Dow Chemical Company
Using ASPUN 6817 polyethylene, the temperature of the spin pack was 460 ° F, the weight ratio of pod to core was 1: 1 and the spin hole throughput was 0.8 GHM. The spunbond material was thermally point bonded to both sides of a melt blown nonwoven web of 100% by weight ASPUN 6814 polyethylene. A melt blown web was made according to U.S. Pat. No. 4,041,203 and the resulting three-layer composite structure was thermally point bonded at a bonding temperature of about 250.degree. The bond pattern had regularly spaced bond areas of 270 bond points per square inch, for a total bond area of about 18%.

Example 4 A composite nonwoven was produced by the process described in Comparative Example 2. However, the temperature of the spin pack is 478 ° F, the temperature of the cooling air is 53 ° F, and the pod of the multicomponent fiber is 95% by weight.
ASPUN 6817 polyethylene (Dow Chemical Company)
And KRATON G-2740 thermoplastic elastomeric block copolymer compound and 5% by weight of melt blown web, 95% by weight ASPUN 6814 polyethylene (Dow C).
Chemical Company) and 5% by weight of KRATON G-2740 thermoplastic elastomeric block copolymer compound.

Example 5 A composite nonwoven fabric was produced by the process described in Comparative Example 2. However, the temperature of the spin pack is 478 ° F, the temperature of the cooling air is 53 ° F, and the pod of the multicomponent fiber is 90% by weight.
ASPUN 6817 polyethylene (Dow Chemical Company)
Melt-blown web consisting of 10% by weight of KRATON G-2740 thermoplastic elastomeric block copolymer compound and 90% by weight of ASPUN 6814 polyethylene (Dow).
Chemical Company) and 10% by weight of KRATON G-2740
It is composed of a thermoplastic elastomeric block copolymer compound.

Example 6 A composite nonwoven fabric was produced by the process described in Comparative Example 2. However, the temperature of the spin pack is 470 ° F, the temperature of the cooling air is 52 ° F, and the pod of the multicomponent fiber is 80% by weight.
ASPUN 6817 polyethylene (Dow Chemical Company)
And KRATON G-2740 thermoplastic elastomeric block copolymer compound and 10% by weight of melt blown web is 80% by weight ASPUN 6814 polyethylene (Dow
Chemical Company) and 20% by weight of KRATON G-2740
It is composed of a thermoplastic elastomeric block copolymer compound.

The fabric samples of Comparative 2 and Examples 4-6 were tested to determine their physical properties. The data is shown in Table 2. The test method for obtaining the data in Table 2 was identical to the test method used to obtain the data in Table 1. Table 2 Properties vs. 2 4 4 5 6 Actual grammage (osy) 1.60 1.60 1.67 1.64 Grab tensile MD peak load (lb) 10.35 17.81 20.89 17.68 MD peak energy (in-lb) 17.60 39.10 38.55 34.15 MD% Elongation 72.91 109.11 94.24 100.48 CD peak load (lb) 9.91 12.11 17.41 16.17 CD peak energy (in-lb) 22.55 30.87 48.56 46.08 CD% elongation 108.23 133.44 152.59 154.86 As can be seen from Table 2, addition of thermoplastic elastomeric copolymer Not only increase the wear resistance of the composite fabric, but also greatly increase the strength properties of the composite fabric. For example, if the peak load is about
Increased to 100%, peak energy increased to about 120%, and elongation increased to about 50%.

Comparative Example 3 A nonwoven fabric comprising continuous bicomponent fibers was produced according to the process described in Comparative Example 1. However, the weight ratio between pod and core is
The pods consisted of 100% by weight 25355 high density polyethylene (manufactured by Dow Chemical Company) and the resulting web was thermally point bonded at a bonding temperature of about 260 ° F.
The bond pattern had regularly spaced bond areas of 270 bond points per square inch with a total bond area of 18%.

Example 7 A nonwoven fabric comprising continuous bicomponent fibers was produced according to the process described in Comparative Example 3. However, pod is 253 of 90% by weight.
It consists of 55 high density polyethylene and 10% by weight of KRATONG-2740 thermoplastic elastomeric block copolymer compound. Example 8 A nonwoven fabric consisting of continuous bicomponent fibers was produced according to the process described in Comparative Example 3. However, pod is 253 of 85% by weight.
It consists of 55 high density polyethylene and 15% by weight of KRATONG-2740 thermoplastic elastomeric block copolymer compound.

Example 9 A nonwoven fabric consisting of continuous bicomponent fibers was produced according to the process described in Comparative Example 3. However, pod is 80% by weight of 253
It consists of 55 high density polyethylene and 20% by weight of KRATONG-2740 thermoplastic elastomeric block copolymer compound. Example 10 A nonwoven fabric comprising continuous bicomponent fibers was produced according to the process described in Example 8. This material was thermally point bonded to both sides of a meltblown nonwoven web of 100% by weight ASPUN 25355 high density polyethylene (manufactured by Dow Chemical Company) suitable for the meltblown web. Melt blown webs were made in accordance with U.S. Pat. No. 4,041,203 and the resulting three-layer composite structure was thermally point bonded at a bonding temperature of about 260.degree. The bond pattern had regularly spaced bond areas of 270 bond points per square inch, for a total bond area of about 18%.

Example 11 A composite nonwoven fabric was produced by the process described in Example 10.
However, the melt-blown web consists of 100% by weight of 3495G polypropylene (Exxon). Comparative Example 3 and Example 7
-11 fabric samples were tested to determine their physical properties. These data were obtained using the same method as described for Comparative Example 1. These data are shown in Table 3. Table 3 Properties vs. Properties 3 Example 7 Example 8 Example 9 Example 10 Example 11 Actual basis weight 1.11 1.20 1.12 1.26 1.58 1.49 Grab tensile MD / CD Average peak energy (in-lb) 34.82 42.27 41.95 53.30 38.24 22.55 MD / CD Load ( lb) 11.50 12.50 12.60 14.20 12.70 8.09 MD trapezoid tear (lb) 10.64 12.34 10.65 10.73 12.43 10.94 CD trapezoid tear (lb) 4.67 5.15 6.17 6.10 5.66 3.27 Martindale wear (cycles / 0.5 'hole) 289 356 487 1041 307 403 Murren burst (psi) 19.9 19.9 20.3 21.2 20.6 21.10 MD drape stiffness (in) 2.83 2.53 2.66 2.72 2.96 2.57 CD drape stiffness (in) 1.60 1.37 1.30 1.47 1.33 1.55 Cup crushing peak load (g) 57 43 44 58 66 89 Cup crushing total energy (g / mm) 1025 794 871 1054 1209 1628 The data for Comparative 3 and the samples of Examples 7-9 shown in Table 3 show that the addition of the thermoplastic elastomeric block copolymer indicates that the strength properties or softness of the fabric was The data in Tables 1 and 2 that increase the abrasion resistance of the fabric without loss. Not inconsistent with. The samples of Examples 10 and 11 are composite fabrics and cannot be compared directly with the other samples in Table 3. Example 10
And data for the 11 samples are provided to show the properties of the composite fabrics made according to some embodiments of the present invention.

Example 12 A composite nonwoven fabric was produced by the process described in Example 10.
However, the pod of the outer layer is 85% by weight of 6811A polyethylene (
Dow Chemical Company) and 15% by weight KRATON G-27
It consists of 40 thermoplastic elastomeric block copolymers. Example 13 A composite nonwoven fabric was produced by the process described in Example 10.
However, the pod of the outer layer is 85% by weight of 6811A polyethylene (
Dow Chemical Company) and 15% by weight KRATON G-27
It consists of 40 thermoplastic elastomeric block copolymers and the melt-blown layer consists of 100% by weight of PD 3445 polypropylene (from Exxon).

The fabric samples of Examples 12 and 13 were tested according to the method described above. Table 4 shows the results. Table 4 CHARACTERISTIC 12 Example 13 actual basis weight 1.88 1.69 Grab Tensile MD / CD Average Peak Energy (in-lb) 44.68 28.18 MDMD / CD Average Peak Load (lb) 16.02 12.86 MD trapezoidal tear (lb) 15.55 11.02 CD trapezoidal Tear (lb) 6.15 4.67 Martindale wear (cycle / 0.5 "hole) 1002 385 MD drape stiffness (in) 2.44 3.95 CD drape stiffness (in) 1.65 1.84 cup crushing / peak load (g) 108 131 cup crushing / total energy ( g / mm) 1879 2382 The data in Table 4 demonstrates the high level of abrasion resistance of composites containing thermoplastic elastomeric block copolymers. It has been shown that composite fabrics having polyethylene in the layer and sheath components exhibit a higher abrasion resistance than the material in which the meltblown layer is made of polypropylene.

While the invention has been described with respect to particular embodiments thereof, those skilled in the art will readily perceive changes, changes and substitutions in these embodiments from the above description. Therefore,
It should be understood that the scope of the present invention is limited only by the claims.

[Brief description of the drawings]

FIG. 1 is a schematic diagram of a processing line for manufacturing a preferred embodiment of the present invention.

FIG. 2 is a schematic diagram showing a cross section of a fiber produced according to a preferred embodiment of the present invention, in which polymer components A and B are arranged side by side.

FIG. 3 is a schematic diagram showing a cross-section of a fiber made according to a preferred embodiment of the present invention, wherein the polymer components A and B have an eccentric sheath / core arrangement.

FIG. 4 is a schematic diagram illustrating a cross-section of a fiber made according to a preferred embodiment of the present invention, wherein the polymer components A and B are arranged in a concentric sheath / core arrangement.

FIG. 5 is a partial perspective view of a sample of a thermally point bonded fabric made in accordance with a preferred embodiment of the present invention.

FIG. 6 is a partial perspective view of a multilayer fabric made according to a preferred embodiment of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 10 Processing line 12 Extruder 14 Hopper 16 Conduit 18 Spinneret 20 Cooling blower 22 Extension device (suction device) 24 Heating device 26 Forming surface 28 Guide roller 30 Vacuum device 32 Compression roller 34 Hot spot coupling roller 42 Winding roller 50 Three-layer nonwoven fabric 52 Intermediate layer 54, 56 Outer layer 58 Joining point

────────────────────────────────────────────────── ─── Continued on front page (72) Inventor Linda Anne Conner United States of America Georgia 30328 Atlanta Spalding Trail 76 (72) Inventor Paul Windsor Estee United States of America Georgia 30131 Cumming Goldmine Road 2905 (72) Inventor Jay Sheldon Schultz United States of America 30076 Roswell Woodline Court 550, Georgia 550 (72) Inventor David Craig Struck 30114 Canton Fox Place, Georgia, United States 251 (56) References JP-A-62-28410 (JP, A) JP-A-52-85575 (JP, A) JP-A-62-33818 (JP, A) JP-A-62-84143 (JP, A) JP-A-2-26973 (JP, A) JP-A-2-259151 (JP, A) JP-A-3-97907 (JP, A) JP-A-3-220356 (JP, A) WO 91/5088 (WO, A1) (58) Fields investigated (Int. Cl. ⁷ , DB name) D04H 1/00-18/00 D01F 8/00-8/18

Claims (22)

(57) [Claims] 1. An extruded multi-component polymer strand comprising first and second polymer components, the multi-component strand having a cross-section, a length, and a peripheral surface,
The first and second components are arranged to occupy substantially separate zones within the cross-section of the multi-component strand and extend continuously along the length of the multi-component strand; A nonwoven fabric comprising at least a portion of the peripheral surface of a multicomponent strand continuously along the length of the component strand and comprising a mixture of a polyolefin, a thermoplastic elastomeric polymer, and a tackifying resin. 2. A first web consisting of an extruded multi-component polymer strand comprising first and second polymer components;
A second web of extruded single-component polymer strands, wherein the multi-component strand has a cross-section, a length, and a peripheral surface, and wherein the first and second components are multi-component. Within the cross section of the strand, the second component is arranged to occupy substantially separate zones and extends continuously along the length of the multi-component strand, with the second component continuously running along the length of the multi-component strand. The monocomponent polymer of the second web comprises at least a portion of the peripheral surface of the multicomponent strand and includes a first mixture of a polyolefin, a thermoplastic elastomeric polymer, and a tackifying resin. A second blend with a thermoplastic elastomeric polymer, wherein the first web and the second web are positioned in a layer-by-layer surface-to-surface relationship and are joined together to form a single piece of fabric Nonwoven, characterized in that is. 3. A and A ′ are each a thermoplastic end block composed of a styrene-based portion, and B is an elastomeric poly (ethylene-butylene) midblock, and the thermoplastic elastomeric polymer is ABA ′. The nonwoven fabric according to claim 1, comprising a block copolymer. 4. The nonwoven fabric according to claim 1, wherein the tackifying resin is selected from the group consisting of a hydrogenated hydrocarbon resin and a terpene hydrocarbon resin. 5. The nonwoven fabric according to claim 1, wherein the mixture also contains a viscosity-reducing polyolefin. 6. The nonwoven fabric according to claim 5, wherein the viscosity reducing polyolefin is a polyethylene wax. 7. A thermoplastic elastomer block wherein A is a thermoplastic end block comprising a styrene-based portion, B is an elastomeric poly (ethylene-butylene) block, and the thermoplastic elastomeric polymer is A
The nonwoven fabric according to claim 3, further comprising a two-block copolymer represented by -B. 8. The nonwoven fabric according to claim 1, wherein the strand is a continuous fiber. 9. The method according to claim 1, wherein the first component has a first melting point, and the second component has a second melting point lower than the first melting point. Non-woven fabric. 10. The first component has a first melting point,
The nonwoven fabric according to claim 1 or 2, wherein the second component has a second melting point lower than the first melting point, and the second component is made of polyethylene. 11. The polyolefin of the second component,
The nonwoven fabric according to claim 1, wherein the nonwoven fabric is selected from the group consisting of polyethylene, polypropylene, and a copolymer of ethylene and propylene. 12. The polyolefin of the second component,
The nonwoven fabric according to claim 1, comprising a linear low-density polyethylene. 13. The first component has a first melting point,
2. The method according to claim 1, wherein said second component has a second melting point lower than said first melting point, and said first component comprises a polyolefin.
2. The nonwoven fabric according to 1. 14. The method of claim 1, wherein the first component has a first melting point.
The second component has a second melting point lower than the first melting point, and the first component is selected from the group consisting of polypropylene and a copolymer of propylene and ethylene, and the second component is selected from the group consisting of: The nonwoven fabric according to claim 1, which is made of polyethylene. 15. The nonwoven fabric of claim 2 , wherein the strands of the second web are made by melt blowing. 16. A third web comprising an extruded multi-component polymer strand comprising first and second polymer components, said multi-component strand having a cross-section, a length, and a peripheral surface. Wherein the first and second components are arranged to occupy substantially separate zones within the cross-section of the multi-component strand and extend continuously along the length of the multi-component strand; Wherein the component comprises at least a portion of the peripheral surface of the multi-component strand continuously along the length of the multi-component strand and comprises a third mixture of a polyolefin and a thermoplastic elastomeric polymer; 3. The nonwoven fabric of claim 2, wherein is bonded to one side of a second web, and a third web is bonded to an opposite side of the second web. 17. The polyolefin of the second component of the first web and the polyolefin of the second web are selected from the group consisting of polyethylene, polypropylene, and copolymers of ethylene and propylene. Nonwoven. 18. An extruded multi-component polymer strand first web comprising first and second polymer components, and an extruded single-component polymer strand second web; The multi-component strand has a cross-section, a length, and a peripheral surface, and the first and second components are arranged to occupy substantially separate zones within the cross-section of the multi-component strand, and The second component extends continuously along the length of the strand, the second component comprising at least a portion of the peripheral surface of the multi-component strand continuously along the length of the multi-component strand, and wherein the second component comprises a polyolefin and a thermoplastic elastomer. A first mixture of a polymer and a tackifying resin, wherein the first web and the second web are positioned in a layer-by-layer surface-to-surface relationship and are joined together to form a single piece of cloth You are Non-woven fabric characterized by. 19. A non-woven fabric comprising an extruded multi-component polymer strand comprising first and second polymer components, the multi-component strand having a cross-section, a length, and a peripheral surface, The first and second components are arranged to occupy substantially separate zones within the cross-section of the multi-component strand and extend continuously along the length of the multi-component strand; It comprises at least a part of the peripheral surface of the multi-component strand continuously along the length of the component strand and comprises a first mixture of polyolefin, thermoplastic elastomeric polymer and tackifying resin. Personal care products. 20. A web comprising an extruded multi-component polymer strand comprising first and second polymer components, and a second web comprising an extruded single-component polymer strand. The multi-component strand has a cross-section, a length, and a peripheral surface, wherein the first and second components are arranged to occupy substantially separate zones within the cross-section of the multi-component strand; The second component extends continuously along the length of the multi-component strand, the second component comprising at least a portion of the peripheral surface of the multi-component strand continuously along the length of the multi-component strand, and comprising a polyolefin and a thermoplastic. A first mixture of an elastomeric polymer and a tackifying resin; the single-component polymer comprises a second mixture of a polyolefin and a thermoplastic elastomeric polymer; No An article of apparel characterized by a layer of nonwoven fabric in which the ebs are positioned in a layered surface-to-surface relationship and are joined together to form a single piece of cloth. 21. An extruded multi-component polymer strand comprising first and second polymer components, wherein the multi-component strand has a cross-section, a length, and a peripheral surface, and wherein the first and second multi-component strands comprise The second component is arranged to occupy substantially separate zones within the cross-section of the multi-component strand and extends continuously along the length of the multi-component strand; at least a portion constitute a 20% of a thermoplastic elastomeric polymer 5% to 95% of the polyolefin and the weight ratio of 80 percent by weight of the multicomponent strands peripheral surface of which the length along continuously and
A nonwoven fabric comprising a mixture of a tackifier resin in a weight ratio of more than 0% and 10% or less . 22. A first web comprising an extruded multi-component polymer strand comprising first and second polymer components, and a second web comprising an extruded single-component polymer strand. The multi-component strand has a cross-section, a length, and a peripheral surface, wherein the first and second components are arranged to occupy substantially separate zones within the cross-section of the multi-component strand; The second component extends continuously along the length of the multi-component strand, and the second component comprises at least a portion of a peripheral surface of the multi-component strand continuously along the length of the multi-component strand, wherein 80% to 95% polyolefin and 5% to 20% thermoplastic elastomeric polymer by weight and tackiness of more than 0% to 10% by weight
A first mixture of the application resin , the single-component polymer includes a second mixture of a polyolefin and a thermoplastic elastomeric polymer, and the first web and the second web are formed into a layered surface pair. An article of apparel comprising a layer of nonwoven fabric positioned in surface relation and joined together to form a single piece of cloth.